Alignment and attachment systems for medical instruments

ABSTRACT

A medical instrument can include alignment and attachment mechanisms for aligning and attaching the medical instrument to another device, such as an adapter on an instrument drive mechanism. For example, a medical system can include a medical instrument having an instrument handle and an elongated body. The system can include an alignment mechanism configured to provide rotational alignment between the medical instrument and an adapter. The system can also include an attachment mechanism configured to secure the medical instrument to the adapter. The attachment mechanism can include at least three locking elements positioned circumferentially about the axis.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/690,744, filed Jun. 27, 2018, which is incorporated herein byreference. Any and all applications for which a foreign or domesticpriority claim is identified in the Application Data Sheet as filed withthe present application are hereby incorporated by reference under 37CFR 1.57.

TECHNICAL FIELD

This application relates to alignment and attachment systems and methodsfor medical instruments. In some embodiments, the alignment andattachment systems and methods can be used with robotic medical systemsand instruments.

BACKGROUND

Medical procedures, such as laparoscopy, may involve accessing andvisualizing an internal region of a patient. In a laparoscopicprocedure, a medical instrument can be inserted into the internal regionthrough a laparoscopic access port.

In certain procedures, a robotically-enabled medical system may be usedto control the insertion and/or manipulation of the medical instrument.The robotically-enabled medical system may include a robotic arm, orother instrument positioning device, to which the medical instrument canbe attached.

SUMMARY

Alignment and attachment systems for medical instruments are describedherein. In some embodiments, the alignment systems are configured toalign a medical instrument with a corresponding adapter, and theattachment systems are configured to attach the medical instrument tothe adapter. The adapter can be positioned on an instrument drivemechanism. The instrument drive mechanism can be positioned on a roboticarm.

In a first aspect, a medical system can include a medical instrumentcomprising an instrument handle and an elongated body, wherein theinstrument handle is configured to attach to an adapter on an instrumentdrive mechanism. The system can also include an alignment mechanismconfigured to provide rotational alignment between the medicalinstrument and the adapter.

The medical system can include one or more of the following features inany combination: (a) wherein the alignment mechanism extends through alongitudinal axis of the instrument handle; (b) wherein the alignmentmechanism comprises an alignment structure on the elongated body; (c)wherein the alignment structure comprises a spiral surface on theelongated body; (d) wherein, when the instrument handle is attached tothe adapter, a distal surface on the instrument handle opposes aproximal surface on the adapter; (e) wherein the instrument drivemechanism is positioned on a robotic arm; (f) wherein the robotic armextends from a bed or a cart; (g) wherein the rotational alignmentresults in at least one locking element being aligned with and insertedinto a corresponding pocket; (h) wherein the locking element ispositioned on the adapter and the pocket is positioned on the handle;(i) wherein the locking element comprises a ball bearing; and/or (j)wherein the rotational alignment is passive.

In another aspect, a medical system can include a medical instrumentconfigured for use during a robotically-enabled medical procedure. Themedical instrument can include an elongated body extending between adistal end and a proximal end, the distal end configured to be insertedinto a patient during a robotically-enabled medical procedure, and aninstrument handle including a proximal face and a distal face, whereinthe elongated body extends through the proximal face and the distalface. The distal face can be configured to attach to an adapter on aninstrument drive mechanism. The medical system can also include analignment mechanism configured to provide rotational alignment betweenthe medical instrument and the adapter. The alignment mechanism caninclude a first alignment structure on the medical instrument, and asecond alignment structure on the adapter. As the medical instrument isattached to the adapter, the first alignment structure can engage thesecond alignment structure to provide the rotational alignment.

The medical system can include one or more of the following features inany combination: (a) wherein, when the instrument handle is attached tothe adapter, the alignment mechanism extends through a longitudinal axisof the instrument handle; (b) wherein the first alignment structurecomprises a spiral surface on the elongated body, and the secondattachment structure comprises a bearing surface within an opening ofthe adapter; (c) wherein the bearing surface comprises a ball bearing;(d) wherein the instrument drive mechanism is positioned on a roboticarm; (e) wherein the robotic arm extends from a bed or a cart; (f)wherein the rotational alignment results in at least one locking elementbeing aligned with and inserted into a corresponding pocket; (g) whereinthe locking element is positioned on the adapter and the pocket ispositioned on the handle; (h) wherein the locking element is positionedon the handle and the pocket is positioned on the adapter; (i) whereinthe locking element comprises a ball bearing; and/or (j) wherein therotational alignment is passive.

In another aspect, a robotic system can include a medical instrumentcomprising an instrument handle and an elongated body, wherein theinstrument handle is configured to attach to an adapter on an instrumentdrive mechanism, and an attachment mechanism configured to secure theinstrument handle to the adapter, wherein, when the instrument handle issecured to the adapter, the elongated body of the medical instrumentextends through an opening in the adapter.

The robotic system can include one or more of the following features inany combination: (a) wherein the attachment mechanism comprises at leastthree locking elements that are circumferentially positioned about theinstrument handle; (b) wherein the attachment mechanism comprises atleast one locking element positioned on the instrument handle that isconfigured to extend into a pocket on the adapter; (c) wherein theattachment mechanism comprises at least one locking element positionedon the adapter that is configured to extend into a pocket on theinstrument handle; (d) wherein the locking element comprises aprotruding member; (e) wherein the protruding member comprises a ballbearing; (f) wherein the protruding member comprises hook; (g) whereinthe protruding member engages a spring-loaded surface in a pocket;and/or (h) wherein the instrument handle is configured to be top loadedonto the adaptor, such that the elongated body of the instrument extendsthrough the opening in the adapter.

In another aspect, a medical system can include a medical instrumentconfigured for use during a robotically-enabled medical procedure, themedical instrument comprising an elongated body extending between adistal end and a proximal end, the distal end configured to be insertedinto a patient during a robotically-enabled medical procedure, and aninstrument handle including a proximal face and a distal face, whereinthe elongated body extends through the proximal face and the distalface, and wherein the distal face is configured to attach to an adapteron an instrument drive mechanism. The medical system can also include anattachment mechanism configured to secure the medical instrument to theadapter, wherein, when the instrument handle is secured to the adapter,the elongated body of the medical instrument extends along an axis fromthe distal face through an opening in the adapter, wherein theattachment mechanism comprises at least three locking elementspositioned circumferentially about the axis.

The medical system can include one or more of the following features inany combination: (a) wherein at least one of the locking elementscomprises a protruding member; (b) wherein the protruding membercomprises a ball bearing; (c) wherein the protruding member compriseshook; and/or (d) wherein the protruding member engages a spring-loadedsurface in a pocket.

In another aspect, a method includes inserting an elongated body of amedical instrument through an opening of an adapter attached to aninstrument drive mechanism; advancing a handle of the medical instrumenttoward the adapter such that an alignment mechanism provides rotationalalignment between the medical instrument and the adapter; and attachingthe handle of the medical instrument to the adapter.

The medical system can include one or more of the following features inany combination: (a) wherein the medical instrument includes a spiralsurface on the elongated body and the adapter includes a bearing surfacein the adapter, and wherein the rotational alignment occurs as thebearing surface contacts the spiral surface; (b) wherein attaching thehandle of the medical instrument to the adapter comprises engaging anattachment mechanism between the handle and the adapter; (c) whereinengaging an attachment mechanism comprises receiving a protruding memberof the attachment mechanism in a pocket of the attachment mechanism; (d)wherein the protruding member is on the handle and the pocket is on theadapter; (e) wherein the protruding member comprises a ball bearing; (f)wherein the protruding member comprises hook; and/or (g) wherein theprotruding member engages a spring-loaded surface in the pocket.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed aspects will hereinafter be described in conjunction withthe appended drawings, provided to illustrate and not to limit thedisclosed aspects, wherein like designations denote like elements.

FIG. 1 illustrates an embodiment of a cart-based robotic system arrangedfor diagnostic and/or therapeutic bronchoscopy procedure(s).

FIG. 2 depicts further aspects of the robotic system of FIG. 1.

FIG. 3 illustrates an embodiment of the robotic system of FIG. 1arranged for ureteroscopy.

FIG. 4 illustrates an embodiment of the robotic system of FIG. 1arranged for a vascular procedure.

FIG. 5 illustrates an embodiment of a table-based robotic systemarranged for a bronchoscopy procedure.

FIG. 6 provides an alternative view of the robotic system of FIG. 5.

FIG. 7 illustrates an example system configured to stow robotic arm(s).

FIG. 8 illustrates an embodiment of a table-based robotic systemconfigured for a ureteroscopy procedure.

FIG. 9 illustrates an embodiment of a table-based robotic systemconfigured for a laparoscopic procedure.

FIG. 10 illustrates an embodiment of the table-based robotic system ofFIGS. 5-9 with pitch or tilt adjustment.

FIG. 11 provides a detailed illustration of the interface between thetable and the column of the table-based robotic system of FIGS. 5-10.

FIG. 12 illustrates an exemplary instrument driver.

FIG. 13 illustrates an exemplary medical instrument with a pairedinstrument driver.

FIG. 14 illustrates an alternative design for an instrument driver andinstrument where the axes of the drive units are parallel to the axis ofthe elongated shaft of the instrument.

FIG. 15 depicts a block diagram illustrating a localization system thatestimates a location of one or more elements of the robotic systems ofFIGS. 1-10, such as the location of the instrument of FIGS. 13 and 14,in accordance to an example embodiment.

FIG. 16A illustrates an embodiment of a medical instrument that includesan alignment mechanism and an attachment mechanism for aligning themedical instrument with and attaching the medical instrument to anadapter on an instrument drive mechanism.

FIG. 16B illustrates an embodiment of an instrument drive mechanismpositioned on a distal end of a robotic arm that extends from a bed.

FIGS. 17A-17D provide detailed views of an embodiment of an alignmentmechanism and an embodiment of an attachment mechanism for aligning amedical instrument with and attaching the medical instrument to anadapter on an instrument drive mechanism.

FIG. 17A is a perspective view of the medical instrument and the adapteron the drive mechanism in an unattached configuration and illustratesthe alignment and attachment mechanisms.

FIG. 17B is a perspective view of a proximal face of the adapter andillustrates an embodiment of a first alignment structure of thealignment mechanism on the adapter and embodiments of locking elementsof the attachment mechanism on the adapter.

FIG. 17C is a perspective view of a distal face of a handle of themedical instrument and illustrates a second alignment structure of thealignment mechanism on the medical instrument and embodiments of pocketsof the attachment mechanism configured to engage with the lockingelements.

FIG. 17D illustrates a view of the distal face of the handle of themedical instrument.

FIGS. 18A-18C provide views of an embodiment of an attachment mechanismduring various stages of an attachment process.

FIG. 18A illustrates a locking element and a pocket of the attachmentmechanism in an unattached configuration.

FIG. 18B illustrates the locking element and the pocket in anintermediary position between the unattached configuration and anattached configuration.

FIG. 18C illustrates the locking element and the pocket in the attachedconfiguration.

FIGS. 19A-19C provide views illustrating an embodiment of a lockingelement that includes a ball bearing.

FIG. 19A is a partially exploded perspective view of the adapter.

FIG. 19B is a perspective view of the adapter illustrating the lockingelement in an assembled configuration.

FIG. 19C is a cross-sectional view of the adapter illustrating thelocking element in an assembled configuration.

FIG. 20 illustrates another embodiment of an attachment mechanism thatincludes spring loaded pinch levers.

FIG. 21 illustrates another embodiment of an attachment mechanism thatincludes cantilever hooks.

FIG. 22 is a perspective view of a proximal face of an embodiment of anadapter and illustrates that an adapter release mechanism can bepositioned on the proximal face.

DETAILED DESCRIPTION 1. Overview

Aspects of the present disclosure may be integrated into arobotically-enabled medical system capable of performing a variety ofmedical procedures, including both minimally invasive, such aslaparoscopy, and non-invasive, such as endoscopy, procedures. Amongendoscopy procedures, the system may be capable of performingbronchoscopy, ureteroscopy, gastroscopy, etc.

In addition to performing the breadth of procedures, the system mayprovide additional benefits, such as enhanced imaging and guidance toassist the physician. Additionally, the system may provide the physicianwith the ability to perform the procedure from an ergonomic positionwithout the need for awkward arm motions and positions. Still further,the system may provide the physician with the ability to perform theprocedure with improved ease of use such that one or more of theinstruments of the system can be controlled by a single user.

Various embodiments will be described below in conjunction with thedrawings for purposes of illustration. It should be appreciated thatmany other implementations of the disclosed concepts are possible, andvarious advantages can be achieved with the disclosed implementations.Headings are included herein for reference and to aid in locatingvarious sections. These headings are not intended to limit the scope ofthe concepts described with respect thereto. Such concepts may haveapplicability throughout the entire specification.

A. Robotic System—Cart.

The robotically-enabled medical system may be configured in a variety ofways depending on the particular procedure. FIG. 1 illustrates anembodiment of a cart-based robotically-enabled system 10 arranged for adiagnostic and/or therapeutic bronchoscopy procedure. During abronchoscopy, the system 10 may comprise a cart 11 having one or morerobotic arms 12 to deliver a medical instrument, such as a steerableendoscope 13, which may be a procedure-specific bronchoscope forbronchoscopy, to a natural orifice access point (i.e., the mouth of thepatient positioned on a table in the present example) to deliverdiagnostic and/or therapeutic tools. As shown, the cart 11 may bepositioned proximate to the patient's upper torso in order to provideaccess to the access point. Similarly, the robotic arms 12 may beactuated to position the bronchoscope relative to the access point. Thearrangement in FIG. 1 may also be utilized when performing agastro-intestinal (GI) procedure with a gastroscope, a specializedendoscope for GI procedures. FIG. 2 depicts an example embodiment of thecart in greater detail.

With continued reference to FIG. 1, once the cart 11 is properlypositioned, the robotic arms 12 may insert the steerable endoscope 13into the patient robotically, manually, or a combination thereof. Asshown, the steerable endoscope 13 may comprise at least two telescopingparts, such as an inner leader portion and an outer sheath portion, eachportion coupled to a separate instrument driver from the set ofinstrument drivers 28, each instrument driver coupled to the distal endof an individual robotic arm. This linear arrangement of the instrumentdrivers 28, which facilitates coaxially aligning the leader portion withthe sheath portion, creates a “virtual rail” 29 that may be repositionedin space by manipulating the one or more robotic arms 12 into differentangles and/or positions. The virtual rails described herein are depictedin the Figures using dashed lines, and accordingly the dashed lines donot depict any physical structure of the system. Translation of theinstrument drivers 28 along the virtual rail 29 telescopes the innerleader portion relative to the outer sheath portion or advances orretracts the endoscope 13 from the patient. The angle of the virtualrail 29 may be adjusted, translated, and pivoted based on clinicalapplication or physician preference. For example, in bronchoscopy, theangle and position of the virtual rail 29 as shown represents acompromise between providing physician access to the endoscope 13 whileminimizing friction that results from bending the endoscope 13 into thepatient's mouth.

The endoscope 13 may be directed down the patient's trachea and lungsafter insertion using precise commands from the robotic system untilreaching the target destination or operative site. In order to enhancenavigation through the patient's lung network and/or reach the desiredtarget, the endoscope 13 may be manipulated to telescopically extend theinner leader portion from the outer sheath portion to obtain enhancedarticulation and greater bend radius. The use of separate instrumentdrivers 28 also allows the leader portion and sheath portion to bedriven independent of each other.

For example, the endoscope 13 may be directed to deliver a biopsy needleto a target, such as, for example, a lesion or nodule within the lungsof a patient. The needle may be deployed down a working channel thatruns the length of the endoscope to obtain a tissue sample to beanalyzed by a pathologist. Depending on the pathology results,additional tools may be deployed down the working channel of theendoscope for additional biopsies. After identifying a nodule to bemalignant, the endoscope 13 may endoscopically deliver tools to resectthe potentially cancerous tissue. In some instances, diagnostic andtherapeutic treatments may need to be delivered in separate procedures.In those circumstances, the endoscope 13 may also be used to deliver afiducial to “mark” the location of the target nodule as well. In otherinstances, diagnostic and therapeutic treatments may be delivered duringthe same procedure.

The system 10 may also include a movable tower 30, which may beconnected via support cables to the cart 11 to provide support forcontrols, electronics, fluidics, optics, sensors, and/or power to thecart 11. Placing such functionality in the tower 30 allows for a smallerform factor cart 11 that may be more easily adjusted and/orre-positioned by an operating physician and his/her staff. Additionally,the division of functionality between the cart/table and the supporttower 30 reduces operating room clutter and facilitates improvingclinical workflow. While the cart 11 may be positioned close to thepatient, the tower 30 may be stowed in a remote location to stay out ofthe way during a procedure.

In support of the robotic systems described above, the tower 30 mayinclude component(s) of a computer-based control system that storescomputer program instructions, for example, within a non-transitorycomputer-readable storage medium such as a persistent magnetic storagedrive, solid state drive, etc. The execution of those instructions,whether the execution occurs in the tower 30 or the cart 11, may controlthe entire system or sub-system(s) thereof. For example, when executedby a processor of the computer system, the instructions may cause thecomponents of the robotics system to actuate the relevant carriages andarm mounts, actuate the robotics arms, and control the medicalinstruments. For example, in response to receiving the control signal,the motors in the joints of the robotics arms may position the arms intoa certain posture.

The tower 30 may also include a pump, flow meter, valve control, and/orfluid access in order to provide controlled irrigation and aspirationcapabilities to system that may be deployed through the endoscope 13.These components may also be controlled using the computer system oftower 30. In some embodiments, irrigation and aspiration capabilitiesmay be delivered directly to the endoscope 13 through separate cable(s).

The tower 30 may include a voltage and surge protector designed toprovide filtered and protected electrical power to the cart 11, therebyavoiding placement of a power transformer and other auxiliary powercomponents in the cart 11, resulting in a smaller, more moveable cart11.

The tower 30 may also include support equipment for the sensors deployedthroughout the robotic system 10. For example, the tower 30 may includeopto-electronics equipment for detecting, receiving, and processing datareceived from the optical sensors or cameras throughout the roboticsystem 10. In combination with the control system, such opto-electronicsequipment may be used to generate real-time images for display in anynumber of consoles deployed throughout the system, including in thetower 30. Similarly, the tower 30 may also include an electronicsubsystem for receiving and processing signals received from deployedelectromagnetic (EM) sensors. The tower 30 may also be used to house andposition an EM field generator for detection by EM sensors in or on themedical instrument.

The tower 30 may also include a console 31 in addition to other consolesavailable in the rest of the system, e.g., console mounted on top of thecart. The console 31 may include a user interface and a display screen,such as a touchscreen, for the physician operator. Consoles in system 10are generally designed to provide both robotic controls as well aspre-operative and real-time information of the procedure, such asnavigational and localization information of the endoscope 13. When theconsole 31 is not the only console available to the physician, it may beused by a second operator, such as a nurse, to monitor the health orvitals of the patient and the operation of system, as well as provideprocedure-specific data, such as navigational and localizationinformation. In other embodiments, the console 30 is housed in a bodythat is separate from the tower 30.

The tower 30 may be coupled to the cart 11 and endoscope 13 through oneor more cables or connections (not shown). In some embodiments, thesupport functionality from the tower 30 may be provided through a singlecable to the cart 11, simplifying and de-cluttering the operating room.In other embodiments, specific functionality may be coupled in separatecabling and connections. For example, while power may be providedthrough a single power cable to the cart, the support for controls,optics, fluidics, and/or navigation may be provided through a separatecable.

FIG. 2 provides a detailed illustration of an embodiment of the cartfrom the cart-based robotically-enabled system shown in FIG. 1. The cart11 generally includes an elongated support structure 14 (often referredto as a “column”), a cart base 15, and a console 16 at the top of thecolumn 14. The column 14 may include one or more carriages, such as acarriage 17 (alternatively “arm support”) for supporting the deploymentof one or more robotic arms 12 (three shown in FIG. 2). The carriage 17may include individually configurable arm mounts that rotate along aperpendicular axis to adjust the base of the robotic arms 12 for betterpositioning relative to the patient. The carriage 17 also includes acarriage interface 19 that allows the carriage 17 to verticallytranslate along the column 14.

The carriage interface 19 is connected to the column 14 through slots,such as slot 20, that are positioned on opposite sides of the column 14to guide the vertical translation of the carriage 17. The slot 20contains a vertical translation interface to position and hold thecarriage at various vertical heights relative to the cart base 15.Vertical translation of the carriage 17 allows the cart 11 to adjust thereach of the robotic arms 12 to meet a variety of table heights, patientsizes, and physician preferences. Similarly, the individuallyconfigurable arm mounts on the carriage 17 allow the robotic arm base 21of robotic arms 12 to be angled in a variety of configurations.

In some embodiments, the slot 20 may be supplemented with slot coversthat are flush and parallel to the slot surface to prevent dirt andfluid ingress into the internal chambers of the column 14 and thevertical translation interface as the carriage 17 vertically translates.The slot covers may be deployed through pairs of spring spoolspositioned near the vertical top and bottom of the slot 20. The coversare coiled within the spools until deployed to extend and retract fromtheir coiled state as the carriage 17 vertically translates up and down.The spring-loading of the spools provides force to retract the coverinto a spool when carriage 17 translates towards the spool, while alsomaintaining a tight seal when the carriage 17 translates away from thespool. The covers may be connected to the carriage 17 using, forexample, brackets in the carriage interface 19 to ensure properextension and retraction of the cover as the carriage 17 translates.

The column 14 may internally comprise mechanisms, such as gears andmotors, that are designed to use a vertically aligned lead screw totranslate the carriage 17 in a mechanized fashion in response to controlsignals generated in response to user inputs, e.g., inputs from theconsole 16.

The robotic arms 12 may generally comprise robotic arm bases 21 and endeffectors 22, separated by a series of linkages 23 that are connected bya series of joints 24, each joint comprising an independent actuator,each actuator comprising an independently controllable motor. Eachindependently controllable joint represents an independent degree offreedom available to the robotic arm. Each of the arms 12 have sevenjoints, and thus provide seven degrees of freedom. A multitude of jointsresult in a multitude of degrees of freedom, allowing for “redundant”degrees of freedom. Redundant degrees of freedom allow the robotic arms12 to position their respective end effectors 22 at a specific position,orientation, and trajectory in space using different linkage positionsand joint angles. This allows for the system to position and direct amedical instrument from a desired point in space while allowing thephysician to move the arm joints into a clinically advantageous positionaway from the patient to create greater access, while avoiding armcollisions.

The cart base 15 balances the weight of the column 14, carriage 17, andarms 12 over the floor. Accordingly, the cart base 15 houses heaviercomponents, such as electronics, motors, power supply, as well ascomponents that either enable movement and/or immobilize the cart. Forexample, the cart base 15 includes rollable wheel-shaped casters 25 thatallow for the cart to easily move around the room prior to a procedure.After reaching the appropriate position, the casters 25 may beimmobilized using wheel locks to hold the cart 11 in place during theprocedure.

Positioned at the vertical end of column 14, the console 16 allows forboth a user interface for receiving user input and a display screen (ora dual-purpose device such as, for example, a touchscreen 26) to providethe physician user with both pre-operative and intra-operative data.Potential pre-operative data on the touchscreen 26 may includepre-operative plans, navigation and mapping data derived frompre-operative computerized tomography (CT) scans, and/or notes frompre-operative patient interviews. Intra-operative data on display mayinclude optical information provided from the tool, sensor andcoordinate information from sensors, as well as vital patientstatistics, such as respiration, heart rate, and/or pulse. The console16 may be positioned and tilted to allow a physician to access theconsole from the side of the column 14 opposite carriage 17. From thisposition, the physician may view the console 16, robotic arms 12, andpatient while operating the console 16 from behind the cart 11. Asshown, the console 16 also includes a handle 27 to assist withmaneuvering and stabilizing cart 11.

FIG. 3 illustrates an embodiment of a robotically-enabled system 10arranged for ureteroscopy. In a ureteroscopic procedure, the cart 11 maybe positioned to deliver a ureteroscope 32, a procedure-specificendoscope designed to traverse a patient's urethra and ureter, to thelower abdominal area of the patient. In a ureteroscopy, it may bedesirable for the ureteroscope 32 to be directly aligned with thepatient's urethra to reduce friction and forces on the sensitive anatomyin the area. As shown, the cart 11 may be aligned at the foot of thetable to allow the robotic arms 12 to position the ureteroscope 32 fordirect linear access to the patient's urethra. From the foot of thetable, the robotic arms 12 may insert the ureteroscope 32 along thevirtual rail 33 directly into the patient's lower abdomen through theurethra.

After insertion into the urethra, using similar control techniques as inbronchoscopy, the ureteroscope 32 may be navigated into the bladder,ureters, and/or kidneys for diagnostic and/or therapeutic applications.For example, the ureteroscope 32 may be directed into the ureter andkidneys to break up kidney stone build up using laser or ultrasoniclithotripsy device deployed down the working channel of the ureteroscope32. After lithotripsy is complete, the resulting stone fragments may beremoved using baskets deployed down the ureteroscope 32.

FIG. 4 illustrates an embodiment of a robotically-enabled systemsimilarly arranged for a vascular procedure. In a vascular procedure,the system 10 may be configured such the cart 11 may deliver a medicalinstrument 34, such as a steerable catheter, to an access point in thefemoral artery in the patient's leg. The femoral artery presents both alarger diameter for navigation as well as relatively less circuitous andtortuous path to the patient's heart, which simplifies navigation. As ina ureteroscopic procedure, the cart 11 may be positioned towards thepatient's legs and lower abdomen to allow the robotic arms 12 to providea virtual rail 35 with direct linear access to the femoral artery accesspoint in the patient's thigh/hip region. After insertion into theartery, the medical instrument 34 may be directed and inserted bytranslating the instrument drivers 28. Alternatively, the cart may bepositioned around the patient's upper abdomen in order to reachalternative vascular access points, such as, for example, the carotidand brachial arteries near the shoulder and wrist.

B. Robotic System—Table.

Embodiments of the robotically-enabled medical system may alsoincorporate the patient's table. Incorporation of the table reduces theamount of capital equipment within the operating room by removing thecart, which allows greater access to the patient. FIG. 5 illustrates anembodiment of such a robotically-enabled system arranged for abronchoscopy procedure. System 36 includes a support structure or column37 for supporting platform 38 (shown as a “table” or “bed”) over thefloor. Much like in the cart-based systems, the end effectors of therobotic arms 39 of the system 36 comprise instrument drivers 42 that aredesigned to manipulate an elongated medical instrument, such as abronchoscope 40 in FIG. 5, through or along a virtual rail 41 formedfrom the linear alignment of the instrument drivers 42. In practice, aC-arm for providing fluoroscopic imaging may be positioned over thepatient's upper abdominal area by placing the emitter and detectoraround table 38.

FIG. 6 provides an alternative view of the system 36 without the patientand medical instrument for discussion purposes. As shown, the column 37may include one or more carriages 43 shown as ring-shaped in the system36, from which the one or more robotic arms 39 may be based. Thecarriages 43 may translate along a vertical column interface 44 thatruns the length of the column 37 to provide different vantage pointsfrom which the robotic arms 39 may be positioned to reach the patient.The carriage(s) 43 may rotate around the column 37 using a mechanicalmotor positioned within the column 37 to allow the robotic arms 39 tohave access to multiples sides of the table 38, such as, for example,both sides of the patient. In embodiments with multiple carriages, thecarriages may be individually positioned on the column and may translateand/or rotate independent of the other carriages. While carriages 43need not surround the column 37 or even be circular, the ring-shape asshown facilitates rotation of the carriages 43 around the column 37while maintaining structural balance. Rotation and translation of thecarriages 43 allows the system to align the medical instruments, such asendoscopes and laparoscopes, into different access points on thepatient. In other embodiments (not shown), the system 36 can include apatient table or bed with adjustable arm supports in the form of bars orrails extending alongside it. One or more robotic arms 39 (e.g., via ashoulder with an elbow joint) can be attached to the adjustable armsupports, which can be vertically adjusted. By providing verticaladjustment, the robotic arms 39 are advantageously capable of beingstowed compactly beneath the patient table or bed, and subsequentlyraised during a procedure.

The arms 39 may be mounted on the carriages through a set of arm mounts45 comprising a series of joints that may individually rotate and/ortelescopically extend to provide additional configurability to therobotic arms 39. Additionally, the arm mounts 45 may be positioned onthe carriages 43 such that, when the carriages 43 are appropriatelyrotated, the arm mounts 45 may be positioned on either the same side oftable 38 (as shown in FIG. 6), on opposite sides of table 38 (as shownin FIG. 9), or on adjacent sides of the table 38 (not shown).

The column 37 structurally provides support for the table 38, and a pathfor vertical translation of the carriages. Internally, the column 37 maybe equipped with lead screws for guiding vertical translation of thecarriages, and motors to mechanize the translation of said carriagesbased the lead screws. The column 37 may also convey power and controlsignals to the carriage 43 and robotic arms 39 mounted thereon.

The table base 46 serves a similar function as the cart base 15 in cart11 shown in FIG. 2, housing heavier components to balance the table/bed38, the column 37, the carriages 43, and the robotic arms 39. The tablebase 46 may also incorporate rigid casters to provide stability duringprocedures. Deployed from the bottom of the table base 46, the castersmay extend in opposite directions on both sides of the base 46 andretract when the system 36 needs to be moved.

Continuing with FIG. 6, the system 36 may also include a tower (notshown) that divides the functionality of system 36 between table andtower to reduce the form factor and bulk of the table. As in earlierdisclosed embodiments, the tower may provide a variety of supportfunctionalities to table, such as processing, computing, and controlcapabilities, power, fluidics, and/or optical and sensor processing. Thetower may also be movable to be positioned away from the patient toimprove physician access and de-clutter the operating room.Additionally, placing components in the tower allows for more storagespace in the table base for potential stowage of the robotic arms. Thetower may also include a master controller or console that provides botha user interface for user input, such as keyboard and/or pendant, aswell as a display screen (or touchscreen) for pre-operative andintra-operative information, such as real-time imaging, navigation, andtracking information. In some embodiments, the tower may also containholders for gas tanks to be used for insufflation.

In some embodiments, a table base may stow and store the robotic armswhen not in use. FIG. 7 illustrates a system 47 that stows robotic armsin an embodiment of the table-based system. In system 47, carriages 48may be vertically translated into base 49 to stow robotic arms 50, armmounts 51, and the carriages 48 within the base 49. Base covers 52 maybe translated and retracted open to deploy the carriages 48, arm mounts51, and arms 50 around column 53, and closed to stow to protect themwhen not in use. The base covers 52 may be sealed with a membrane 54along the edges of its opening to prevent dirt and fluid ingress whenclosed.

FIG. 8 illustrates an embodiment of a robotically-enabled table-basedsystem configured for a ureteroscopy procedure. In a ureteroscopy, thetable 38 may include a swivel portion 55 for positioning a patientoff-angle from the column 37 and table base 46. The swivel portion 55may rotate or pivot around a pivot point (e.g., located below thepatient's head) in order to position the bottom portion of the swivelportion 55 away from the column 37. For example, the pivoting of theswivel portion 55 allows a C-arm (not shown) to be positioned over thepatient's lower abdomen without competing for space with the column (notshown) below table 38. By rotating the carriage 35 (not shown) aroundthe column 37, the robotic arms 39 may directly insert a ureteroscope 56along a virtual rail 57 into the patient's groin area to reach theurethra. In a ureteroscopy, stirrups 58 may also be fixed to the swivelportion 55 of the table 38 to support the position of the patient's legsduring the procedure and allow clear access to the patient's groin area.

In a laparoscopic procedure, through small incision(s) in the patient'sabdominal wall, minimally invasive instruments may be inserted into thepatient's anatomy. In some embodiments, the minimally invasiveinstruments comprise an elongated rigid member, such as a shaft, whichis used to access anatomy within the patient. After inflation of thepatient's abdominal cavity, the instruments may be directed to performsurgical or medical tasks, such as grasping, cutting, ablating,suturing, etc. In some embodiments, the instruments can comprise ascope, such as a laparoscope. FIG. 9 illustrates an embodiment of arobotically-enabled table-based system configured for a laparoscopicprocedure. As shown in FIG. 9, the carriages 43 of the system 36 may berotated and vertically adjusted to position pairs of the robotic arms 39on opposite sides of the table 38, such that instrument 59 may bepositioned using the arm mounts 45 to be passed through minimalincisions on both sides of the patient to reach his/her abdominalcavity.

To accommodate laparoscopic procedures, the robotically-enabled tablesystem may also tilt the platform to a desired angle. FIG. 10illustrates an embodiment of the robotically-enabled medical system withpitch or tilt adjustment. As shown in FIG. 10, the system 36 mayaccommodate tilt of the table 38 to position one portion of the table ata greater distance from the floor than the other. Additionally, the armmounts 45 may rotate to match the tilt such that the arms 39 maintainthe same planar relationship with table 38. To accommodate steeperangles, the column 37 may also include telescoping portions 60 thatallow vertical extension of column 37 to keep the table 38 from touchingthe floor or colliding with base 46.

FIG. 11 provides a detailed illustration of the interface between thetable 38 and the column 37. Pitch rotation mechanism 61 may beconfigured to alter the pitch angle of the table 38 relative to thecolumn 37 in multiple degrees of freedom. The pitch rotation mechanism61 may be enabled by the positioning of orthogonal axes 1, 2 at thecolumn-table interface, each axis actuated by a separate motor 3, 4responsive to an electrical pitch angle command. Rotation along onescrew 5 would enable tilt adjustments in one axis 1, while rotationalong the other screw 6 would enable tilt adjustments along the otheraxis 2. In some embodiments, a ball joint can be used to alter the pitchangle of the table 38 relative to the column 37 in multiple degrees offreedom.

For example, pitch adjustments are particularly useful when trying toposition the table in a Trendelenburg position, i.e., position thepatient's lower abdomen at a higher position from the floor than thepatient's lower abdomen, for lower abdominal surgery. The Trendelenburgposition causes the patient's internal organs to slide towards his/herupper abdomen through the force of gravity, clearing out the abdominalcavity for minimally invasive tools to enter and perform lower abdominalsurgical or medical procedures, such as laparoscopic prostatectomy.

C. Instrument Driver & Interface.

The end effectors of the system's robotic arms comprise (i) aninstrument driver (alternatively referred to as “instrument drivemechanism” or “instrument device manipulator”) that incorporateelectro-mechanical means for actuating the medical instrument and (ii) aremovable or detachable medical instrument, which may be devoid of anyelectro-mechanical components, such as motors. This dichotomy may bedriven by the need to sterilize medical instruments used in medicalprocedures, and the inability to adequately sterilize expensive capitalequipment due to their intricate mechanical assemblies and sensitiveelectronics. Accordingly, the medical instruments may be designed to bedetached, removed, and interchanged from the instrument driver (and thusthe system) for individual sterilization or disposal by the physician orthe physician's staff. In contrast, the instrument drivers need not bechanged or sterilized, and may be draped for protection.

FIG. 12 illustrates an example instrument driver. Positioned at thedistal end of a robotic arm, instrument driver 62 comprises of one ormore drive units 63 arranged with parallel axes to provide controlledtorque to a medical instrument via drive shafts 64. Each drive unit 63comprises an individual drive shaft 64 for interacting with theinstrument, a gear head 65 for converting the motor shaft rotation to adesired torque, a motor 66 for generating the drive torque, an encoder67 to measure the speed of the motor shaft and provide feedback to thecontrol circuitry, and control circuitry 68 for receiving controlsignals and actuating the drive unit. Each drive unit 63 beingindependent controlled and motorized, the instrument driver 62 mayprovide multiple (four as shown in FIG. 12) independent drive outputs tothe medical instrument. In operation, the control circuitry 68 wouldreceive a control signal, transmit a motor signal to the motor 66,compare the resulting motor speed as measured by the encoder 67 with thedesired speed, and modulate the motor signal to generate the desiredtorque.

For procedures that require a sterile environment, the robotic systemmay incorporate a drive interface, such as a sterile adapter connectedto a sterile drape, that sits between the instrument driver and themedical instrument. The chief purpose of the sterile adapter is totransfer angular motion from the drive shafts of the instrument driverto the drive inputs of the instrument while maintaining physicalseparation, and thus sterility, between the drive shafts and driveinputs. Accordingly, an example sterile adapter may comprise of a seriesof rotational inputs and outputs intended to be mated with the driveshafts of the instrument driver and drive inputs on the instrument.Connected to the sterile adapter, the sterile drape, comprised of athin, flexible material such as transparent or translucent plastic, isdesigned to cover the capital equipment, such as the instrument driver,robotic arm, and cart (in a cart-based system) or table (in atable-based system). Use of the drape would allow the capital equipmentto be positioned proximate to the patient while still being located inan area not requiring sterilization (i.e., non-sterile field). On theother side of the sterile drape, the medical instrument may interfacewith the patient in an area requiring sterilization (i.e., sterilefield).

D. Medical Instrument.

FIG. 13 illustrates an example medical instrument with a pairedinstrument driver. Like other instruments designed for use with arobotic system, medical instrument 70 comprises an elongated shaft 71(or elongated body) and an instrument base 72. The instrument base 72,also referred to as an “instrument handle” due to its intended designfor manual interaction by the physician, may generally compriserotatable drive inputs 73, e.g., receptacles, pulleys or spools, thatare designed to be mated with drive outputs 74 that extend through adrive interface on instrument driver 75 at the distal end of robotic arm76. When physically connected, latched, and/or coupled, the mated driveinputs 73 of instrument base 72 may share axes of rotation with thedrive outputs 74 in the instrument driver 75 to allow the transfer oftorque from drive outputs 74 to drive inputs 73. In some embodiments,the drive outputs 74 may comprise splines that are designed to mate withreceptacles on the drive inputs 73.

The elongated shaft 71 is designed to be delivered through either ananatomical opening or lumen, e.g., as in endoscopy, or a minimallyinvasive incision, e.g., as in laparoscopy. The elongated shaft 71 maybe either flexible (e.g., having properties similar to an endoscope) orrigid (e.g., having properties similar to a laparoscope) or contain acustomized combination of both flexible and rigid portions. Whendesigned for laparoscopy, the distal end of a rigid elongated shaft maybe connected to an end effector extending from a jointed wrist formedfrom a clevis with at least one degree of freedom and a surgical tool ormedical instrument, such as, for example, a grasper or scissors, thatmay be actuated based on force from the tendons as the drive inputsrotate in response to torque received from the drive outputs 74 of theinstrument driver 75. When designed for endoscopy, the distal end of aflexible elongated shaft may include a steerable or controllable bendingsection that may be articulated and bent based on torque received fromthe drive outputs 74 of the instrument driver 75.

Torque from the instrument driver 75 is transmitted down the elongatedshaft 71 using tendons along the shaft 71. These individual tendons,such as pull wires, may be individually anchored to individual driveinputs 73 within the instrument handle 72. From the handle 72, thetendons are directed down one or more pull lumens along the elongatedshaft 71 and anchored at the distal portion of the elongated shaft 71,or in the wrist at the distal portion of the elongated shaft. During asurgical procedure, such as a laparoscopic, endoscopic or hybridprocedure, these tendons may be coupled to a distally mounted endeffector, such as a wrist, grasper, or scissor. Under such anarrangement, torque exerted on drive inputs 73 would transfer tension tothe tendon, thereby causing the end effector to actuate in some way. Insome embodiments, during a surgical procedure, the tendon may cause ajoint to rotate about an axis, thereby causing the end effector to movein one direction or another. Alternatively, the tendon may be connectedto one or more jaws of a grasper at distal end of the elongated shaft71, where tension from the tendon cause the grasper to close.

In endoscopy, the tendons may be coupled to a bending or articulatingsection positioned along the elongated shaft 71 (e.g., at the distalend) via adhesive, control ring, or other mechanical fixation. Whenfixedly attached to the distal end of a bending section, torque exertedon drive inputs 73 would be transmitted down the tendons, causing thesofter, bending section (sometimes referred to as the articulablesection or region) to bend or articulate. Along the non-bendingsections, it may be advantageous to spiral or helix the individual pulllumens that direct the individual tendons along (or inside) the walls ofthe endoscope shaft to balance the radial forces that result fromtension in the pull wires. The angle of the spiraling and/or spacingthere between may be altered or engineered for specific purposes,wherein tighter spiraling exhibits lesser shaft compression under loadforces, while lower amounts of spiraling results in greater shaftcompression under load forces, but also exhibits limits bending. On theother end of the spectrum, the pull lumens may be directed parallel tothe longitudinal axis of the elongated shaft 71 to allow for controlledarticulation in the desired bending or articulable sections.

In endoscopy, the elongated shaft 71 houses a number of components toassist with the robotic procedure. The shaft may comprise of a workingchannel for deploying surgical tools (or medical instruments),irrigation, and/or aspiration to the operative region at the distal endof the shaft 71. The shaft 71 may also accommodate wires and/or opticalfibers to transfer signals to/from an optical assembly at the distaltip, which may include of an optical camera. The shaft 71 may alsoaccommodate optical fibers to carry light from proximally-located lightsources, such as light emitting diodes, to the distal end of the shaft.

At the distal end of the instrument 70, the distal tip may also comprisethe opening of a working channel for delivering tools for diagnosticand/or therapy, irrigation, and aspiration to an operative site. Thedistal tip may also include a port for a camera, such as a fiberscope ora digital camera, to capture images of an internal anatomical space.Relatedly, the distal tip may also include ports for light sources forilluminating the anatomical space when using the camera.

In the example of FIG. 13, the drive shaft axes, and thus the driveinput axes, are orthogonal to the axis of the elongated shaft. Thisarrangement, however, complicates roll capabilities for the elongatedshaft 71. Rolling the elongated shaft 71 along its axis while keepingthe drive inputs 73 static results in undesirable tangling of thetendons as they extend off the drive inputs 73 and enter pull lumenswithin the elongated shaft 71. The resulting entanglement of suchtendons may disrupt any control algorithms intended to predict movementof the flexible elongated shaft during an endoscopic procedure.

FIG. 14 illustrates an alternative design for an instrument driver andinstrument where the axes of the drive units are parallel to the axis ofthe elongated shaft of the instrument. As shown, a circular instrumentdriver 80 comprises four drive units with their drive outputs 81 alignedin parallel at the end of a robotic arm 82. The drive units, and theirrespective drive outputs 81, are housed in a rotational assembly 83 ofthe instrument driver 80 that is driven by one of the drive units withinthe assembly 83. In response to torque provided by the rotational driveunit, the rotational assembly 83 rotates along a circular bearing thatconnects the rotational assembly 83 to the non-rotational portion 84 ofthe instrument driver. Power and controls signals may be communicatedfrom the non-rotational portion 84 of the instrument driver 80 to therotational assembly 83 through electrical contacts may be maintainedthrough rotation by a brushed slip ring connection (not shown). In otherembodiments, the rotational assembly 83 may be responsive to a separatedrive unit that is integrated into the non-rotatable portion 84, andthus not in parallel to the other drive units. The rotational mechanism83 allows the instrument driver 80 to rotate the drive units, and theirrespective drive outputs 81, as a single unit around an instrumentdriver axis 85.

Like earlier disclosed embodiments, an instrument 86 may comprise anelongated shaft portion 88 and an instrument base 87 (shown with atransparent external skin for discussion purposes) comprising aplurality of drive inputs 89 (such as receptacles, pulleys, and spools)that are configured to receive the drive outputs 81 in the instrumentdriver 80. Unlike prior disclosed embodiments, instrument shaft 88extends from the center of instrument base 87 with an axis substantiallyparallel to the axes of the drive inputs 89, rather than orthogonal asin the design of FIG. 13.

When coupled to the rotational assembly 83 of the instrument driver 80,the medical instrument 86, comprising instrument base 87 and instrumentshaft 88, rotates in combination with the rotational assembly 83 aboutthe instrument driver axis 85. Since the instrument shaft 88 ispositioned at the center of instrument base 87, the instrument shaft 88is coaxial with instrument driver axis 85 when attached. Thus, rotationof the rotational assembly 83 causes the instrument shaft 88 to rotateabout its own longitudinal axis. Moreover, as the instrument base 87rotates with the instrument shaft 88, any tendons connected to the driveinputs 89 in the instrument base 87 are not tangled during rotation.Accordingly, the parallelism of the axes of the drive outputs 81, driveinputs 89, and instrument shaft 88 allows for the shaft rotation withouttangling any control tendons.

E. Navigation and Control.

Traditional endoscopy may involve the use of fluoroscopy (e.g., as maybe delivered through a C-arm) and other forms of radiation-based imagingmodalities to provide endoluminal guidance to an operator physician. Incontrast, the robotic systems contemplated by this disclosure canprovide for non-radiation-based navigational and localization means toreduce physician exposure to radiation and reduce the amount ofequipment within the operating room. As used herein, the term“localization” may refer to determining and/or monitoring the positionof objects in a reference coordinate system. Technologies such aspre-operative mapping, computer vision, real-time EM tracking, and robotcommand data may be used individually or in combination to achieve aradiation-free operating environment. In other cases, whereradiation-based imaging modalities are still used, the pre-operativemapping, computer vision, real-time EM tracking, and robot command datamay be used individually or in combination to improve upon theinformation obtained solely through radiation-based imaging modalities.

FIG. 15 is a block diagram illustrating a localization system 90 thatestimates a location of one or more elements of the robotic system, suchas the location of the instrument, in accordance to an exampleembodiment. The localization system 90 may be a set of one or morecomputer devices configured to execute one or more instructions. Thecomputer devices may be embodied by a processor (or processors) andcomputer-readable memory in one or more components discussed above. Byway of example and not limitation, the computer devices may be in thetower 30 shown in FIG. 1, the cart shown in FIGS. 1-4, the beds shown inFIGS. 5-10, etc.

As shown in FIG. 15, the localization system 90 may include alocalization module 95 that processes input data 91-94 to generatelocation data 96 for the distal tip of a medical instrument. Thelocation data 96 may be data or logic that represents a location and/ororientation of the distal end of the instrument relative to a frame ofreference. The frame of reference can be a frame of reference relativeto the anatomy of the patient or to a known object, such as an EM fieldgenerator (see discussion below for the EM field generator).

The various input data 91-94 are now described in greater detail.Pre-operative mapping may be accomplished through the use of thecollection of low dose CT scans. Pre-operative CT scans arereconstructed into three-dimensional images, which are visualized, e.g.as “slices” of a cutaway view of the patient's internal anatomy. Whenanalyzed in the aggregate, image-based models for anatomical cavities,spaces and structures of the patient's anatomy, such as a patient lungnetwork, may be generated. Techniques such as center-line geometry maybe determined and approximated from the CT images to develop athree-dimensional volume of the patient's anatomy, referred to as modeldata 91 (also referred to as “preoperative model data” when generatedusing only preoperative CT scans). The use of center-line geometry isdiscussed in U.S. patent application Ser. No. 14/523,760, the contentsof which are herein incorporated in its entirety. Network topologicalmodels may also be derived from the CT-images, and are particularlyappropriate for bronchoscopy.

In some embodiments, the instrument may be equipped with a camera toprovide vision data 92. The localization module 95 may process thevision data to enable one or more vision-based location tracking. Forexample, the preoperative model data may be used in conjunction with thevision data 92 to enable computer vision-based tracking of the medicalinstrument (e.g., an endoscope or an instrument advance through aworking channel of the endoscope). For example, using the preoperativemodel data 91, the robotic system may generate a library of expectedendoscopic images from the model based on the expected path of travel ofthe endoscope, each image linked to a location within the model.Intra-operatively, this library may be referenced by the robotic systemin order to compare real-time images captured at the camera (e.g., acamera at a distal end of the endoscope) to those in the image libraryto assist localization.

Other computer vision-based tracking techniques use feature tracking todetermine motion of the camera, and thus the endoscope. Some features ofthe localization module 95 may identify circular geometries in thepreoperative model data 91 that correspond to anatomical lumens andtrack the change of those geometries to determine which anatomical lumenwas selected, as well as the relative rotational and/or translationalmotion of the camera. Use of a topological map may further enhancevision-based algorithms or techniques.

Optical flow, another computer vision-based technique, may analyze thedisplacement and translation of image pixels in a video sequence in thevision data 92 to infer camera movement. Examples of optical flowtechniques may include motion detection, object segmentationcalculations, luminance, motion compensated encoding, stereo disparitymeasurement, etc. Through the comparison of multiple frames overmultiple iterations, movement and location of the camera (and thus theendoscope) may be determined.

The localization module 95 may use real-time EM tracking to generate areal-time location of the endoscope in a global coordinate system thatmay be registered to the patient's anatomy, represented by thepreoperative model. In EM tracking, an EM sensor (or tracker) comprisingof one or more sensor coils embedded in one or more locations andorientations in a medical instrument (e.g., an endoscopic tool) measuresthe variation in the EM field created by one or more static EM fieldgenerators positioned at a known location. The location informationdetected by the EM sensors is stored as EM data 93. The EM fieldgenerator (or transmitter), may be placed close to the patient to createa low intensity magnetic field that the embedded sensor may detect. Themagnetic field induces small currents in the sensor coils of the EMsensor, which may be analyzed to determine the distance and anglebetween the EM sensor and the EM field generator. These distances andorientations may be intra-operatively “registered” to the patientanatomy (e.g., the preoperative model) in order to determine thegeometric transformation that aligns a single location in the coordinatesystem with a position in the pre-operative model of the patient'sanatomy. Once registered, an embedded EM tracker in one or morepositions of the medical instrument (e.g., the distal tip of anendoscope) may provide real-time indications of the progression of themedical instrument through the patient's anatomy.

Robotic command and kinematics data 94 may also be used by thelocalization module 95 to provide localization data 96 for the roboticsystem. Device pitch and yaw resulting from articulation commands may bedetermined during pre-operative calibration. Intra-operatively, thesecalibration measurements may be used in combination with known insertiondepth information to estimate the position of the instrument.Alternatively, these calculations may be analyzed in combination withEM, vision, and/or topological modeling to estimate the position of themedical instrument within the network.

As FIG. 15 shows, a number of other input data can be used by thelocalization module 95. For example, although not shown in FIG. 15, aninstrument utilizing shape-sensing fiber can provide shape data that thelocalization module 95 can use to determine the location and shape ofthe instrument.

The localization module 95 may use the input data 91-94 incombination(s). In some cases, such a combination may use aprobabilistic approach where the localization module 95 assigns aconfidence weight to the location determined from each of the input data91-94. Thus, where the EM data may not be reliable (as may be the casewhere there is EM interference) the confidence of the locationdetermined by the EM data 93 can be decrease and the localization module95 may rely more heavily on the vision data 92 and/or the roboticcommand and kinematics data 94.

As discussed above, the robotic systems discussed herein may be designedto incorporate a combination of one or more of the technologies above.The robotic system's computer-based control system, based in the tower,bed and/or cart, may store computer program instructions, for example,within a non-transitory computer-readable storage medium such as apersistent magnetic storage drive, solid state drive, or the like, that,upon execution, cause the system to receive and analyze sensor data anduser commands, generate control signals throughout the system, anddisplay the navigational and localization data, such as the position ofthe instrument within the global coordinate system, anatomical map, etc.

2. Alignment and Attachment Mechanisms for Medical Instruments

Medical instruments, such as those described above, can includealignment and attachment mechanisms as described in this section. Insome embodiments, the alignment and attachment mechanisms provide noveland efficient mechanisms for aligning and attaching an instrument (see,e.g., FIG. 16A) to a robotic arm (see, e.g., FIG. 16B). In someembodiments, the instrument is capable of attaching directly to aninstrument drive mechanism of the robotic arm, while in otherembodiments, the instrument handle is capable of attaching to an adapterthat serves as an interface between the instrument drive mechanism andthe instrument. In some embodiments, the adapter helps to maintainsterility in a sterile procedure.

The alignment mechanisms can be configured to facilitate correctlyorienting the medical instrument to the component to which the medicalinstrument will attach. For example, the alignment mechanism can provideproper rotational alignment between the medical instrument and theinstrument drive mechanism and/or the adapter. In some embodiments, thealignment mechanism also provides proper translational alignment. Properalignment between the instrument and the instrument drive mechanismand/or the adapter can facilitate connection of the attachmentmechanism. For example, proper alignment can facilitate properengagement between locking features of the attachment mechanism on theinstrument with corresponding locking features of the attachmentmechanism on the instrument drive mechanism and/or the adapter.

The attachment mechanisms can be configured to provide a secure andstable connection between the medical instrument and the instrumentdrive mechanism and/or the adapter. As will be described in more detailbelow with reference to certain example embodiments illustrated in thefigures, the attachment mechanisms can provide circumferential lockingwith multiple points of connection. For example, in some embodiments,the attachment mechanism comprises two, three, four, five, or morelocking features that can be positioned circumferentially around an axisof the instrument, instrument drive mechanism, and/or the adapter. Insome embodiments, the instrument comprises a through-loaded instrumentthat includes an elongated body that extends along an axis that isthrough-loaded through a channel, bore, or other opening in theinstrument drive mechanism and/or the adapter. The attachment mechanismcan include locking features positioned on a handle of the instrumentcircumferentially around the axis of the elongated body. The attachmentmechanism can also include corresponding locking features positioned onthe instrument drive mechanism and/or the adapter circumferentiallyaround the channel, bore, or other opening.

As will become more fully apparent from the following description, insome embodiments, an advantage of the alignment and attachmentmechanisms described herein is that the mechanisms provide improved orincreased attachment strength for the instruments. In some embodiments,the mechanisms described herein provide that the instrument is verysecurely attached and the attachment is stable and/or stiff. Further, insome embodiments, the mechanisms are configured to provide this stableattachment using a limited or minimal number of machined and metalcomponents. This can reduce manufacturing cost and simplifymanufacturing processes.

In addition, in some embodiments, the alignment and attachmentmechanisms described herein can advantageously require a relatively lowforce to attach and/or release the instrument to and/or from theinstrument drive mechanism or adapter when desired. For example, in someembodiments, the instruments can advantageously be removed or attachedwith one hand. In some embodiments, the instruments can advantageouslybe removed or attached when the robotic arm is in any position ororientation. Accordingly, attachment and detachment of the instrumentcan be performed in a controlled and/or ergonomic manner.

In many of the examples described herein, the alignment and attachmentmechanisms are described as providing alignment and attachment betweenthe medical instrument and the adapter. However, in some embodiments,the adapter can be omitted, and the alignment and attachment mechanismscan provide alignment and attachment between the medical instrument andthe instrument drive mechanism directly, for example, with nointermediary adapter. Further, in some embodiments, the alignment andattachment mechanisms can be configured to provide alignment andattachment between the medical instrument (or even other non-medicalinstruments) and any other components to which the instrument can beattached. Thus, the illustrated and described embodiments should beunderstood as merely providing certain non-limiting examples.

FIG. 16A illustrates an embodiment of a medical instrument 100. FIG. 16Billustrates an embodiment of a medical system 120 that includes roboticarms 122 having instrument drive mechanisms 124 and adapters 126positioned thereon. As shown in FIGS. 16A and 16B, the medicalinstrument 100 and the medical system 120 include an alignment mechanism140 and an attachment mechanism 160. The alignment mechanism 140 isconfigured to provide proper orientation between the medical instrument100 and the instrument drive mechanism 124 and adapter 126, and theattachment mechanism 160 is configured to provide a secure connectionbetween the medical instrument 100 and the instrument drive mechanism124 and adapter 126.

FIG. 16A illustrates a side view of the instrument 100. In theillustrated embodiment, the instrument 100 includes an elongated body102 and a handle 104. The elongated body 102 extends between a distalend 103 and a proximal end 105. As used herein, the term distal refersto a location or position that is located toward the end of theinstrument that is inserted into or otherwise interacts with a patientduring a procedure, and the term proximal refers to a location orposition that is located in the opposite direction, away from the end ofthe instrument that is inserted into the patient.

As shown, an end effector 108, which in the illustrated embodiment isconfigured as a grasper, can be positioned at the distal end 103 of theelongated body 102. In other embodiments, the instrument may includeother types of end effectors, such as scissors, clippers, ligationtools, cauterizing tools, basketing tools, etc. In some embodiments, forexample, as illustrated, the end effector 108 is connected to the distalend of the elongated body 102 by a wrist 106. The wrist 106 can beconfigured to allow one or more degrees of freedom for the instrument100. For example, the wrist 106 can be a two degree-of-freedom wrist. Asan example, a two degree-of-freedom wrist can allow the end effector 108to pivot or rotate around a pitch axis and a yaw axis. In someembodiments, the wrist 106 can be fixed, so as to provide zero degreesof freedom. In some embodiments, the wrist 106 may allow one, two,three, or more degrees of freedom.

As shown in FIG. 16A, the instrument 100 includes the handle 104. Thehandle 104 can be configured to connect to the instrument drivemechanism 124 or adapter 126 shown in FIG. 16B. As previously mentioned,the instrument 100 may include one or more tendons, cables, or pullwires that extend along (e.g., through or on) the elongated body 102between the end effector 108 and the handle 104. The handle 104 mayinclude one or more drive inputs configured to engage one or more driveoutputs on the instrument drive mechanism (see FIG. 14) that allow theinstrument drive mechanism to actuate (e.g., tension or pull) the pullwires. Actuating the pull wires can cause motion of the end effector 108to allow for remote manipulation and control of the end effector 108.For example, in some embodiments, actuation of the pull wires can beconfigured to cause jaws of the end effector 108 to open and closeand/or to allow the end effector 108 to rotate about pitch or yaw axes.As mentioned above, the instrument drive mechanism can be positioned ona robotic arm 122 (see FIG. 16B). In some embodiments, the robotic arm122 can be controlled to position, roll, advance, and/or retract theinstrument 100.

The elongated body 102 can extend through the handle 104 as illustratedin FIG. 16A. In some such embodiments, the elongated body 102 can beconfigured to advance or retract relative to the handle 104, althoughthis need not always be the case. In some embodiments, the instrumentdrive mechanism 124 is configured to cause the elongated body 102 toadvance or retract relative to the handle 104. This can allow, forexample, the handle 104 to remain stationary while the elongated body102 and end effector 108 are advanced into a patient during a procedure.In some embodiments, the proximal end of the elongated body 102 isattached to the handle 104 such that the elongated body 102 extends onlybetween the end effector 108 and the handle 104.

As illustrated in FIG. 16A, the handle 104 can include a distal face109. In some embodiments, the alignment mechanism 140 includescomponents that extend from the distal face 109. These components caninteract or engage with corresponding components of the alignmentmechanism 140 on the adapter 126 to provide alignment between theinstrument 100 and the adapter 126 when the instrument 100 is attachedto the adapter 126. In some embodiments, the attachment mechanism 160includes components that are positioned on the distal face 109 of thehandle 104. These components can interact or engage with correspondingcomponents of the attachment mechanism 160 on the adapter 126 to providea connection between the instrument 100 and the adapter 126. Thealignment mechanism 140 and the attachment mechanism 160 are shown ingreater detail in the embodiment illustrated in FIGS. 17A-17D, which aredescribed in greater detail below.

As noted above, FIG. 16B illustrates a view of an embodiment of themedical system 120. In the illustrated embodiment, the medical system120 includes a plurality of robotic arms 122. Each of the robotic arms122 includes an instrument drive mechanism 124 positioned on a distalend. As illustrated, the instrument drive mechanism 124 includes adistal face 128 and a proximal face 130. Again, the term distal is usedto refer to a direction or position toward the patient, and the termproximal is used to refer to a direction or position away from thepatient.

In some embodiments, the instrument 100 is configured to be throughloaded onto the instrument drive mechanism 124. For example, theinstrument drive mechanism 124 can include a channel, bore, or otheropening (not visible) extending through the instrument drive mechanism124 from the proximal face 130 to the distal face 128, and theinstrument can be through-loaded (or top loaded) onto the instrumentdrive mechanism by inserting the distal end 103 of the elongated body102 through the proximal face 130, through the channel, and out throughthe distal face 128. The instrument 100 can be then be moved distallyuntil the distal face 109 of the handle 104 contacts and engages withthe proximal face 130 of the instrument drive mechanism 124. In someembodiments, the system 120 includes the adapter 126 positioned on theproximal face 130 of the instrument drive mechanism 124. In suchembodiments, the distal face 109 of the handle 104 can contact andengage with the adapter 126. As mentioned previously, the adapter 126may be a sterile adapter configured to maintain sterility between theinstrument 100 and the instrument drive mechanism 124. Through-loadingor top-loading the instrument 100 in this manner advantageously allowsthe instrument 100 to be detached from the instrument drive mechanism124 in a proximal direction, by pulling the instrument 100 away from thepatient. This can advantageously improve patient safety as theinstrument 100 can be removed in a direction that is away from thepatient.

Further, as will be described below, the alignment mechanism 140 on theinstrument 100 and the adapter 126 and/or instrument drive mechanism 124can provide alignment as the instrument is through loaded onto theinstrument drive mechanism 124. For example, as the instrument 100 islowered distally through the instrument drive mechanism 124, alignmentfeatures on the instrument 100 engage with alignment features on theadapter 126 or instrument drive mechanism 124. These features canautomatically cause the instrument 100 to rotate into the correctrotational alignment with the adapter 126 or instrument drive mechanism124. In some embodiments, alignment occurs automatically. In someembodiments, alignment occurs passively. Passive alignment can includealignment that occurs naturally as the instrument 100 and adapter 126 orinstrument drive mechanism 124 are brought together. In someembodiments, the alignment mechanism 140 also provides translationalalignment between the instrument 100 and the adapter 126 or instrumentdrive mechanism 124. For example, the alignment mechanism 140 cancoaxially align an axis of the instrument 100 with an axis of theadapter 126 or instrument drive mechanism 124.

Alignment, provided by the alignment mechanism 140, can facilitateproper orientation of the attachment mechanism 160. For example, thealignment can ensure that locking features of the attachment mechanism160 on the distal face 109 of the instrument 100 align withcorresponding locking features of the attachment mechanism 160 on theproximal face 130 of the adapter 126 or instrument drive mechanism 124such that these features can engage when the distal face 109 is broughtinto contact with the proximal face 130. In some embodiments, engagementof these features can occur automatically or passively. As noted above,a more detailed example of the alignment mechanism 140 and theattachment mechanism 160 will be described in greater detail below withreference to FIGS. 17A-17D.

In the illustrated embodiment of FIG. 16B, the system 120 includes apatient platform 132 or bed that is supported from below by a column 134or other support and a base 136. As shown, in some embodiments, therobotic arms 122 can be attached to the column 134 or base 136 at aposition below the patient platform 132. In some embodiments, therobotic arms 122 can be attached to an adjustable arm support 138, andthe adjustable arm support 138 can be attached to the column 134 or base136 at a position below the patient platform 132. This configurationallows the robotic arms 122 to be deployed from a position below thepatient platform 132. In some embodiments, the alignment mechanisms 140and attachment mechanisms 160 described herein are particularlyadvantageous in these types of systems (for example, as illustrated inFIG. 16B). For example, in some embodiments of the system 120, theinstrument drive mechanism 124 allows for the attached instrument 100 tohave infinite roll via a motor in the instrument drive mechanism 124,which should be accommodated by the attachment mechanism 160. Inaddition, the instrument 100 should be able to both rapidly attach anddetach from the robotic arm 122.

FIGS. 17A-17D provide detailed views of an embodiment of the alignmentmechanism 140 and an embodiment of the attachment mechanism 160. FIG.17A is a perspective view of the medical instrument 100 and the adapter126 on the drive mechanism 124 in an unattached configuration. FIG. 17Bis a perspective view of the proximal face 130 of the adapter 126. FIG.17C is a perspective view of a distal face 109 of the handle 104 of themedical instrument 100. FIG. 17D illustrates a view of the distal face109 of the handle 104 of the medical instrument 100. Example alignmentmechanisms 140 and attachment mechanisms 160 will be described withreference to these figures in the following sections.

B. Example Alignment Mechanisms

As shown in FIGS. 17A-17D, the instrument handle 104 and the adapter 126include the alignment mechanism 140. For example, as illustrated, thealignment mechanism 140 can include a first alignment structure 142 onthe instrument 100 (see FIGS. 17A and 17C) and a second alignmentstructure 144 on the adapter 126 (see FIG. 17B). As will be describedbelow, the first alignment structure 142 can be configured to engage orcontact the second alignment structure 144 as the instrument 100 isthough loaded onto the instrument drive mechanism 124.

As best seen in FIGS. 17A and 17C, in the illustrated embodiment, thefirst alignment structure 142 comprises a shaft 146 that extends fromthe distal face 109 of the handle 104. The elongated body 102 of theinstrument 100 may extend through the shaft 146 (FIG. 17C). The shaft146 can have a length that extends from the distal face 109 for adistance that allows the shaft 146 to extend into the channel 148 of theadapter 126 (and/or instrument drive mechanism 124) as shown in FIG.17A. In some embodiments, the shaft 146 is sufficiently long such thatit extends entirely through the instrument drive mechanism 124. In someembodiments, the shaft 146 extends partly through instrument drivemechanism 124.

The first alignment structure 142 also comprises an alignment surface149 formed on an exterior surface of the shaft 146. As will be describedbelow, the alignment surface 149 engages and contacts the secondalignment structure 144 as the instrument 100 is through loaded onto theinstrument drive mechanism 124 to provide alignment. In someembodiments, the alignment surface 149 is configured as an angledsurface. The angled surface may be formed as a surface that lies in aplane that is not orthogonal to a longitudinal axis of the shaft 146. Insome embodiments, the alignment surface 149 is configured as a spiralsurface. The spiraled surface may spiral around the longitudinal axis ofthe shaft 146 in a helical or spiral manner.

In the illustrated embodiment, the first alignment structure 142 alsoincludes an alignment groove 150. The alignment groove 150 is alsoconfigured to contact and engage with the second alignment structure 144to provide alignment between the instrument 100 and the adapter 126 orinstrument drive mechanism 124. The alignment groove 150 may extendalong and be formed into the exterior surface of the shaft 146. In someembodiments, the alignment groove 150 may extend along the shaft 146toward the handle 104 starting from the distal most point of thealignment surface 149 (i.e., a point along the alignment surface 149that is closest to the handle 104). For example, in some embodiments,the alignment surface 149 is angled with respect to the longitudinalaxis of the shaft 146 such that a first portion of the alignment surface149 is positioned proximally relative to a second portion of thealignment surface 149 that is positioned distally. The groove 150 mayextend toward the handle 104 from the second portion of the alignmentsurface 149.

As illustrated in FIG. 17B, the adapter 126 includes the secondalignment structure 144. The second alignment structure 144 can includea protrusion 152 extending from an inner wall of the channel 148. Insome embodiments, the protrusion 152 can be integrally formed with theinner wall of the channel 148. In some embodiments, the protrusion 152can be formed as a separate piece attached to or extending through theinner wall of the channel 148. In some embodiments, the protrusion 152comprises a portion of a ball bearing that extends through the innerwall of the channel 148. The protrusion 152 contacts and interacts withthe alignment surface 149 and alignment groove 150 as the instrument 100is through loaded onto the adapter 126 to provide alignment between theinstrument 100 and the adapter 126.

For example, the adapter 126 can be attached to the proximal face of theinstrument drive mechanism 124. The distal end 103 of the elongated body102 of the instrument 100 can be inserted into the channel 148 throughthe proximal face 130 in the adapter. The instrument 100 is moved in adistal direction bringing the distal face 109 of the handle 104 towardthe proximal face 130 of the adapter 126. Eventually, the shaft 146 ofthe first alignment structure 142 enters the channel 148. Inserting theshaft 146 of the first alignment structure 142 into the channel 148 canprovide translational alignment between the instrument 100 and theadapter 126; however, at this stage, the instrument 100 may not beproperly rotationally aligned with the adapter 126. As the instrument100 is moved further in the distal direction, the protrusion 152 of thesecond alignment structure 144 is brought into contact with thealignment surface 149 of the first alignment structure 142. Theprotrusion 152 rides along the alignment surface 149 causing theinstrument 100 to rotate into the correct orientation. In someembodiments, the causes passive, automatic, or natural alignment. Theprotrusion 152 eventually reaches the distally lowest most point of thealignment surface 149. At this point the instrument 100 is in the properrotationally aligned position. This allows the protrusion 152 to enterthe alignment groove 150. The alignment groove 150 is sufficientlynarrow such that further rotation of the instrument 100 is limited orprohibited. The instrument 100 can then be moved all the way in thedistal direction until the distal face 109 of the handle 104 contactsthe proximal face 130 of the adapter.

In the aligned position, various features of the instrument handle 104are aligned with corresponding features of the adapter 126 (and/orinstrument drive mechanism 124). These features can include, forexample, the corresponding locking features of the attachment mechanism160 described in greater detail below. The aligned features can alsoinclude, for example, drive outputs 156 (see FIGS. 17A and 17B) on theadapter 126 or instrument drive mechanism 124 that are configured toengage with corresponding drive inputs 158 (see FIGS. 17C and 17D) onthe instrument handle 104. The drive outputs 156 can engage the driveinputs to control the instrument 100 as described above with referenceto FIGS. 13-14. In some embodiments, the drive outputs 156 and driveinputs 158 are configured with a shape that includes some draft (e.g., acone-like shape) to facilitate alignment and engagement. In theembodiments illustrated in FIGS. 17A-17C, the instrument handle 104 andadapter 126 include five drive outputs 156 and five corresponding driveinputs 158. The embodiment illustrated in FIG. 17D includes six driveinputs 158.

The aligned features can also include, for example, a computer-readabletag, such as RFID tag 161 (see FIG. 17D), on the instrument 100 and acorresponding reader 162 (see FIG. 17A) on the adapter 126 or theinstrument drive mechanism 124. In some embodiments, the RFID tag 161 isincluded on the instrument handle 104 within a channel, recess, orpocket. The RFID tag 161 can be configured to provide a wirelessidentification of the instrument 100 to the system 120. It can provideparameters to the system 120, and can allow for authentication andtracking of the instrument 100. The reader 162 may be configured toprotrude into the channel to access and read the RFID tag 161. Inaddition, the alignment mechanism 140 can comprise one or more sensors164 (FIG. 17C). The sensors 164 can be configured to detect thealignment of the elongated body 102 and correctly align it using theinfinite roll of the instrument 100.

In some embodiments, the first alignment structure 142 and the secondalignment structure 144 can be reversed. For example, the alignmentsurface 149 and alignment groove 150 can be included within the channel148 on the adapter 126, and the protrusion 152 can be included on theshaft 146 of the instrument handle 104. Other suitable alignmentstructures are also possible. For example, other suitable alignmentsensors can include key tabs, which may or may not be passive, but willonly engage when aligned properly.

As described herein, the instrument handle 104 can include the alignmentmechanism 140 to enable the instrument handle 104 to quickly attach tothe adapter 126, thereby aligning the attachment mechanism 160 and othercomponents. The alignment mechanism 140 can be in the form of a spiralalignment formed on the instrument shaft. In some embodiments, thealignment mechanism 140 is in the form of a double spiral. The alignmentmechanism 140 can quickly align the instrument handle 104 to the adapter126, thereby providing a quick connect feature that allows for easyexchange of instruments 100 on the robotic arms 122.

B. Example Attachment Mechanisms

As shown in FIGS. 17A-17D, the instrument handle 104 and the adapter 126include the attachment mechanism 160. For example, as illustrated, theattachment mechanism 160 can include locking elements 166 on the adapter126 or instrument drive mechanism 124 (see FIGS. 17A and 17C) andcorresponding pockets 168 on the instrument 100 (see FIGS. 17C and 17D).As will be described below, locking elements 166 are configured to bereceived within and engage with the pockets 168 to attach the instrumenthandle 104 to the adapter 126. As discussed above, the alignmentmechanism 140 is configured to facilitate alignment of these features.

As shown in FIG. 17A, the adapter 126 (or the instrument drive mechanism124) can include the plurality of locking elements 166. In theillustrated embodiment, the adapter 126 includes three locking elements166, although other numbers of locking elements 166 may be used in otherembodiments. For example, the adapter 126 may include two, three, four,five, six or more locking elements 166. The locking elements 166 canextend or project outwardly from the proximal face 130 of the adapter126.

Advantageously, the locking elements 166 can be positionedcircumferentially around the longitudinal axis of the adapter 126. Forexample, the locking elements 166 can be positioned circumferentiallyaround the channel 148. The locking elements 166, when arrangedcircumferentially, can provide locking around the perimeter of theadapter 126. This can provide a connection with improved stability overembodiments that includes only a single locking element or lockingelements only on a single side of the device. In some embodiments,circumferentially positioned locking elements 166 can be evenly spaced.In some embodiments, the spacing need not be even.

In some embodiments, the locking elements 166 of the adapter 126comprise radial locking elements. For example, the locking elements 166can protrude outwardly from the proximal surface of the adapter, and canbe configured to engage a spring loaded surface before being received inthe pockets 168. Engagement between the locking elements 166 and thepockets can include a radial force that maintains the connection.

In the illustrated embodiment of FIGS. 17A-17D, the locking elements 166comprise a ball bearing. These embodiments are shown in greater detailin FIGS. 18A-19C, which are described below. However, the lockingelements 166 can be any type of radial locking element that creates aninterlock. In some embodiments, the locking elements can be in the formof a spring tab. Such an embodiment is shown in FIG. 20 described below.In some embodiments, the locking elements 166 can be in the form of acantilever hook. Such an embodiment is shown in FIG. 21 described below.

As shown in FIGS. 17C and 17D, the distal face 109 of the instrumenthandle 104 includes pockets 168 configured to receive and engage withthe locking elements 166. In the illustrated embodiment, the instrumenthandle 104 includes three pockets 168 so as to engage with the threelocking elements 166 illustrated in FIG. 17A. Of course, otherembodiments may include other numbers of pockets 168 so as to correspondwith the number of locking elements used on the adapter 126.

In some embodiments, the attachment mechanism 160 not only allows aquick connection between the instrument handle 104 and the adapter 126,but it also allow for easy separation or removal, simply by pulling theinstrument handle 104 away from the adapter 126. As mentioned above, thehandle 104 is pulled away from the adapter 126 in a proximal direction(away from the patient), which can be advantageous, as there is littleto no likelihood that the patient may be accidentally stabbed by a sharpinstrument.

While the embodiments described above show the adapter 126 as havinglocking elements 166 protruding therefrom and pockets 168 formed on theinstrument handle 104, in other embodiments, these features can bereversed. For example, the instrument handle 104 can include protrudinglocking elements 166 and the adapter 126 can include pockets. In someembodiments, each of the instrument handle 104 and the adapter 126include both locking elements 166 and pockets 168.

FIGS. 18A-18C provide additional detailed views of the locking elements166 and pockets 168 of the attachment mechanism 160 illustrated in FIGS.17A-17D. In this embodiment, the locking elements 166 include ballbearings 172 which are retained within a flange 170 that extends fromthe adapter 126. FIGS. 19A-19C described below illustrate how anembodiment with a ball bearings 172 which are retained within a flange170 can be manufactured.

As illustrated in FIGS. 18A-18C, the pocket 168 can include a retainingsurface 174. The retaining surface 174 can be configured to move ortranslate in a radial direction (up and down in the orientationillustrated in FIGS. 18A-18C. The retaining surface 174 can have aprofile configured to correspond to the shape of the ball bearing 172.The retaining surface 174 can be biased in a radially outward (e.g.,downward with reference to the orientation of the figures) direction.Biasing can be accomplished, for example, by use of a spring (notillustrated).

The pocket 168 can also include a collar 176. The collar 176 can includea ramped or sloped surface 178 as illustrated. The collar 176 can bemoveable in the proximal and distal direction (e.g., right and leftrelative to the orientation of the figures). The collar 176 can bebiased in the distal direction (e.g., toward the right in the figure),for example, by a spring (not illustrated). Interaction of the ballbearing 172, retaining surface 174, and collar 176 can allow forconnection and disconnection of the locking element 166 to and from thepocket 168.

Example attachment will be described with reference to FIGS. 18A-18C.FIG. 18A illustrates the locking element 166 and the pocket 168 of theattachment mechanism 160 in an unattached configuration. FIG. 18Billustrates the locking element 166 and the pocket 168 in anintermediary position between the unattached configuration and anattached configuration. And, FIG. 18C illustrates the locking element166 and the pocket 168 in the attached configuration. As illustrated,when the instrument handle 104 is inserted onto the adapter 126, thespring loaded internal collar 176 is pushed proximally inside of thecase or housing of the instrument handle 104 (FIG. 19B). When the ballbearing 172 of the locking element 166 is aligned with a cup feature onthe retaining surface 174, the ball bearing 172 moves into the cup andthe collar 176 slides back down (FIG. 19C). In this position (FIG. 18C),the locking element 166 is secured within the pocket 168.

To detach, the collar 176 and the instrument handle 104 can be pulledproximally concurrently. When the collar 176 is retracted far enough forthe slope or ramp surface 178 of the collar 176 to allow the ballbearing 172 to escape from the cup feature of the retaining surface 174,the locking element 166 disengages with the pocket 168 allowing theinstrument 100 to be smoothly disconnected.

FIGS. 19A-19C provide multiple views of an example assembly of thelocking element 166, although other embodiments are possible. Theexample assembly of FIGS. 19A-19C comprises a locking element 166, thatincludes a ball bearing 172 and a flange 170, on an adapter 126. In thisembodiment, the ball bearing 172 is captured within the flange 170between components of two layers or stacked plates of the adapter 126.FIG. 19A is a partially exploded perspective view of the adapter 126.FIG. 19B is a perspective view of the adapter 126 illustrating thelocking element 166 in an assembled configuration. FIG. 19C is across-sectional view of the adapter 126 illustrating the locking element166 in the assembled configuration.

As shown in FIG. 19A, the adapter 126 can comprise a stacked plateconstruction comprising a proximal plate 191 and a distal plate 1292 Theflange 170 can extend from the proximal plate 191. The flange 170includes a bore or hole extending there through for receiving the ballbearing 172. In the illustrated embodiment, the ball bearing 172 can beinserted into the flange 170 from the outer radial side of the flange170. A protrusion 195 prevents the ball bearing 172 from being pushedall the way through the flange. As shown in the cross-sectional view ofFIG. 19C, the protrusion 195 narrows the diameter of the hole throughthe flange 170 such that the ball bearing 172 cannot pass through theradial inner side of the flange.

The distal plate 192 can include a backstop 193, formed as a projectionextending from the distal plate 192. When assembled, as shown in FIG.19B, the backstop 193 extends through a corresponding opening 194 (asshown in FIG. 19A) in the proximal plate 191. In this position, thebackstop 193 can retain the ball bearing 172 within the flange 170.

FIG. 20 illustrates another embodiment of an attachment mechanism 160.In this embodiment, the instrument handle 104 includes pinch levers 180.The pinch levers 180 can be attached to the instrument handle 104 byhinges 182 about which the pinch levers can pivot. A spring element 185can be positioned to bias the pinch levers to a radially outwardposition in which a hooked end 184 of the pinch lever 180 engages acantilever hook 186 that extends from the adapter 126.

To engage the attachment mechanism 160, the instrument handle is movedtowards the adapter 126. The outer surface of the cantilever hooks 186deflects the pinch levers 180 inward allowing the hooked ends 184 topass and engage the cantilever hooks 186. To disengage, the pinch levers180 can be pressed inwardly to such that the hooked ends 184 move freeof the cantilever hooks 186.

FIG. 21 illustrates another embodiment of an attachment mechanism 160that includes a stamped metal element 188 that is securely attached tothe adapter 126. The instrument handle 104 includes a cantilever hook187 that engages with an opening in the stamped metal element 188. Thestamped metal element can be configured to be levered in and out bycantilever hook to allow for attachment.

FIG. 22 is a perspective view of the proximal face 130 of an embodimentof the adapter 126 and illustrates that, in some embodiments, an adapterrelease mechanism 190 can be positioned on the proximal face 130. Theadapter release mechanism 190 can be configured to be actuable torelease the adapter 126 from the instrument drive mechanism 124. Theadapter release mechanism 190 can be, for example, a button or slidetoggle. Inclusion of the adapter release mechanism 190 on the proximalface 130 may prevent accidental removal of the adapter 126 because theadapter release mechanism 190 is inaccessible when the 100 is attachedto the adapter 126. In other embodiments, the adapter release mechanism190 may be included on other portions of the adapter 126, includingportions that are accessible when the instrument 100 is attached to theadapter.

3. Implementing Systems and Terminology

Implementations disclosed herein provide systems, methods and apparatusfor robotically-enabled medical systems. Various implementationsdescribed herein include robotically-enabled medical systems with highforce instruments.

It should be noted that the terms “couple,” “coupling,” “coupled” orother variations of the word couple as used herein may indicate eitheran indirect connection or a direct connection. For example, if a firstcomponent is “coupled” to a second component, the first component may beeither indirectly connected to the second component via anothercomponent or directly connected to the second component.

The position estimation and robotic motion actuation functions describedherein may be stored as one or more instructions on a processor-readableor computer-readable medium. The term “computer-readable medium” refersto any available medium that can be accessed by a computer or processor.By way of example, and not limitation, such a medium may comprise randomaccess memory (RAM), read-only memory (ROM), electrically erasableprogrammable read-only memory (EEPROM), flash memory, compact discread-only memory (CD-ROM) or other optical disk storage, magnetic diskstorage or other magnetic storage devices, or any other medium that canbe used to store desired program code in the form of instructions ordata structures and that can be accessed by a computer. It should benoted that a computer-readable medium may be tangible andnon-transitory. As used herein, the term “code” may refer to software,instructions, code or data that is/are executable by a computing deviceor processor.

The methods disclosed herein comprise one or more steps or actions forachieving the described method. The method steps and/or actions may beinterchanged with one another without departing from the scope of theclaims. In other words, unless a specific order of steps or actions isrequired for proper operation of the method that is being described, theorder and/or use of specific steps and/or actions may be modifiedwithout departing from the scope of the claims.

As used herein, the term “plurality” denotes two or more. For example, aplurality of components indicates two or more components. The term“determining” encompasses a wide variety of actions and, therefore,“determining” can include calculating, computing, processing, deriving,investigating, looking up (e.g., looking up in a table, a database oranother data structure), ascertaining and the like. Also, “determining”can include receiving (e.g., receiving information), accessing (e.g.,accessing data in a memory) and the like. Also, “determining” caninclude resolving, selecting, choosing, establishing and the like.

The phrase “based on” does not mean “based only on,” unless expresslyspecified otherwise. In other words, the phrase “based on” describesboth “based only on” and “based at least on.”

As used herein, the term “approximately” or “about” refers to a range ofmeasurements of a length, thickness, a quantity, time period, or othermeasurable value. Such range of measurements encompasses variations of+/−10% or less, preferably +/−5% or less, more preferably +/−1% or less,and still more preferably +/−0.1% or less, of and from the specifiedvalue, in so far as such variations are appropriate in order to functionin the disclosed devices, systems, and techniques.

The previous description of the disclosed implementations is provided toenable any person skilled in the art to make or use the presentinvention. Various modifications to these implementations will bereadily apparent to those skilled in the art, and the generic principlesdefined herein may be applied to other implementations without departingfrom the scope of the invention. For example, it will be appreciatedthat one of ordinary skill in the art will be able to employ a numbercorresponding alternative and equivalent structural details, such asequivalent ways of fastening, mounting, coupling, or engaging toolcomponents, equivalent mechanisms for producing particular actuationmotions, and equivalent mechanisms for delivering electrical energy.Thus, the present invention is not intended to be limited to theimplementations shown herein but is to be accorded the widest scopeconsistent with the principles and novel features disclosed herein.

What is claimed is:
 1. A medical system, comprising: a medicalinstrument comprising an instrument handle and an elongated body,wherein the instrument handle is configured to attach to an adapter onan instrument drive mechanism such that a plurality of drive inputs onthe instrument handle engage with a corresponding plurality ofinstrument drive outputs of the adapter; and an alignment mechanismcomprising an alignment surface on the elongated body configured torotate the instrument handle during attachment of the instrument handleto the adapter to provide rotational alignment between the medicalinstrument and the adapter such that the plurality of drive inputs arealigned with the plurality of drive outputs.
 2. The system of claim 1,wherein the alignment mechanism extends along a longitudinal axis of theinstrument handle.
 3. The system of claim 1, wherein the alignmentsurface comprises a spiral surface on the elongated body.
 4. The systemof claim 1, wherein, when the instrument handle is attached to theadapter, a distal surface on the instrument handle opposes a proximalsurface on the adapter.
 5. The system of claim 1, wherein the instrumentdrive mechanism is positioned on a robotic arm.
 6. The system of claim5, wherein the robotic arm extends from a bed or a cart.
 7. The systemof claim 1, wherein the rotational alignment results in at least onelocking element being aligned with and inserted into a correspondingpocket.
 8. The system of claim 7, wherein the locking element ispositioned on the adapter and the pocket is positioned on the handle. 9.The system of claim 7, wherein the locking element comprises a ballbearing.
 10. The system of claim 1, wherein the rotational alignment ispassive.
 11. A medical system, comprising: a medical instrumentconfigured for use during a robotically-enabled medical procedure, themedical instrument comprising: an elongated body extending between adistal end and a proximal end, the distal end configured to be insertedinto a patient during a robotically-enabled medical procedure, and aninstrument handle including a proximal face and a distal face, whereinthe elongated body extends through the proximal face and the distalface, wherein the instrument handle comprises a plurality of driveinputs, wherein the distal face is configured to attach to an adapter onan instrument drive mechanism, and wherein the instrument drivemechanism comprises a plurality of drive outputs configured to engagewith the plurality of drive inputs; and an alignment mechanismconfigured to rotate the instrument handle during attachment of theinstrument handle to the adapter to provide rotational alignment betweenthe medical instrument and the adapter, the alignment mechanismcomprising: a first alignment structure on the medical instrument,wherein the first alignment structure comprises an alignment surface onthe elongated body, and a second alignment structure on the adapter,wherein, as the medical instrument is attached to the adapter, the firstalignment structure engages the second alignment structure to providethe rotational alignment such that the plurality of drive inputs on theinstrument handle engage with the plurality of instrument drive outputsof the adapter.
 12. The system of claim 11, wherein, when the instrumenthandle is attached to the adapter, the alignment mechanism extends alonga longitudinal axis of the instrument handle.
 13. The system of claim11, wherein the first alignment surface comprises a spiral surface onthe elongated body, and the second attachment structure comprises abearing surface within an opening of adapter.
 14. The system of claim13, wherein the bearing surface comprises a ball bearing.
 15. The systemof claim 11, wherein the instrument drive mechanism is positioned on arobotic arm.
 16. The system of claim 15, wherein the robotic arm extendsfrom a bed or a cart.
 17. The system of claim 11, wherein the rotationalalignment results in at least one locking element being aligned with andinserted into a corresponding pocket.
 18. The system of claim 17,wherein the locking element is positioned on the adapter and the pocketis positioned on the handle.
 19. The system of claim 17, wherein thelocking element is positioned on the handle and the pocket is positionedon the adapter.